Apparatus for cell constructions



Nov. 17, 1959 J. v. CARLISLE ET AL 2,912,750

APPARATUS FOR CELL CONSTRUCTIONS 4 Sheets-Sheet 1 Filed March 9, 1955 INVENTORS JAMES CARL/$1.5

THEODORE I. ARNOLD A non/v5 Y Nov. 17, 1959 Filed March 9, 1955 J. v. CARLISLE ET AL APPARATUS FOR CELL CONSTRUCTIONS 4 Sheets-Sheet 2 INVENTORS JAMES M CARL/SLE THEODORE M. ARNOLD imam ATTORNEY Nov. 17, 1959 J. v. CARLISLE ET AL 2,912,750

' APPARATUS FOR CELL CONSTRUCTIONS Filed March 9, 1955 4 Sheets-Sheet 3 um f I: 1111 1: Mia;

= 24 '31 34, L m 1 I I K\\ l 26 .36,

INVENTORS JAMES V. CARL/5L5 THEODORE M. ARA/0L0 ATTORNEY Nov. 17, 1959 J. v. CARLISLE ET AL 2,912,750

APPARATUS FOR CELL CONSTRUCTIONS 4 Sheets-Sheet;

Filed March 9, 1955 INVENTORS JAMES l CARL/SL5 rusooone M. ARA/0L0 ATTORNEY United States PatcntO APPARATUS FOR CELL CONSTRUCTIONS James V. Carlisle, Baton Rouge, La., and Theodore M.

Arnold, Kalamazoo, Mich., assignors to Ethyl Corporation, New York, N.Y., a corporation of Delaware Application March 9, 1955, Serial No. 493,156

Claims. (Cl. 29-256) This invention pertains to a new and novel method for the construction of electrolytic cells and in particular is concerned with an apparatus to be employed in the construction of these cells.

The manufacture of sodium and other alkali metals is carried out in an electrolytic cell which is basically similar to the Downs cell described in U. S. Patent 1,501,756. Briefly, the cell includes a housing containing one or more anodes each of which is surrounded by a cylindrical cathode. anode and the surrounding internal surface of the cathode is positioned a foraminous diaphragm supported from above by what is commonly referred to as the collector. The collector, or collector portion corresponding to a single anode comprises an outlet port for removal of the gaseous halogen and an annular inverted channel for manifolding and removal of the alkali metal. This collector is supported by a frame which in turn is attached to and supported by the cell housing.

The concentricity and vertical disposition of the anodes with the surrounding diaphragm and cathode surface is an important attribute of a properly constructed cell. Attaining this objective has been a long standing problem in the industry. Inherent difficulties in the construction of these cells has been the lack of a suitable method for positioning the cathode, with respect to the anode, and for positioning the diaphragm located in the annular space between each anode and cathode. Because of the fact that the cathode and the diaphragm surround substantially the entire length of the anode, it is quite diflicult to position the diaphragm in between the cathode and anode within proper tolerances so as to provide the most efiicient construction of the cell for operation. This can be appreciated when it is noted that ordinarily the lateral distance between the anode and cathode is of the order of only 1 /2 inches and for best operation the diaphragm must be inserted equidistant from the anode and cathode over the entire length of the anode, which is about 3 to 4 feet or more in length. Prior methods employed for achieving this result have not been adequate. Generally speaking, the life period, that is the period before the cell need be broken down for rebuilding, has been erratic and necessitated completely dismantling the cell to replace the diaphragms. Such dismantling and reconstruction, in addition to being inherently expensive, also results in reducing production capacity of a plant. A plant installation consists of a relatively large number of cells occupying specific floor positions or stalls. When a cell is necessarily replaced it unfortunately cannot be merely lifted from the production space or stall occupied, but must be torn down and rebuilt.

In the annular space between an.

for this dismantling and building of a new cell, the production space is, of course, unused.

Until the present invention, the techniques incell building left much to be desired, as above explained. Consequently, it is an object of the present invention to provide apparatus for the rapid and accurate construction of an electrolytic cell. A further object of this invention is to provide apparatus to be employed in constructing an electrolytic cell which will provide a cell having a longer life, higher efficiency, and increased productivity. A particular object of this invention is to provide apparatus for gaging collectors for cells having four anodes and determining the existence of collector dimensions and relationship within desired tolerances. A further object is to provide apparatus for registering a gaged collector for assembly to a collector support frame in a predetermined spatial relationship. A specific-object is to provide apparatus for assembling the collector to the collector frame in accurate alignment so that when inserted into the cell housing, proper positioning of a multi unit cathode with respect to the anodes and the diaphragms is within prescribed tolerances. A further object is to provide apparatus for providing a further gaging of a collector for determining its suitability for reception of diaphragms, and also for locating a set of diaphragms by a predetermined pattern and assembling to a collector-collector support frame sub-assembly. Other objects will be apparent from the discussion hereinafter.

The above and additional objects of this invention are provided by the apparatus described herein. The apparatus includes a device for gaging a collector with respect to the plan disposition of four cylindrical collector portstherein, and concurrently registering the collector and a collector support frame for establishing a cell subassembly. This apparatus is desirably employed in combination with a further apparatus which provides a secondary gaging of the collector, particularly with respect to the roundness of the collector ports, and further concurrently positions a set of diaphragms vertically and horizontally and provides for their assembly to a collectorcollector support frame sub-assembly. In a still more specific embodiment of the invention the foregoing apparatus operates in conjunction with further apparatus for positioning the actual anodes of a cell, for positioning the cathode unit with respect to the anode, and for establishing reference assembly marks to provide for assembly of a collector-collector support frame-diaphragms assembly in predetermined spatial relationship to an assembly comprising the other major components of a cell, viz., the anodes and cathode unit.

It has been found that the apparatus of this invention provides an efficient means for the construction of an electrolytic cell whereby the criticality of the positioning of the cathode with respect to the anodes, and the diaphragms with respect to the cathode and anodes, is achieved. The

apparatus eliminates incorrect alignment of these integral During the time required parts which results, for example, in burning of the dia phragms causing loss of production and necessitating dismantling for reconstruction. Further, the efliciency of the cell is considerably increased as evidenced by the fact that production is increased for a given current input. In additon, the average life of the diaphragms is appreciably increased, thereby reducing loss in production time.

The apparatus is capable of assuming a variety of forms which will be readily understood from the details described below and the accompanying figures, including Figure 1 which shows in exploded fashion the major components of a cell, the sequence of assembly of the components into a completed cell, and the relation of the apparatus of the present invention to the several major components or sub-assemblies of a cell, and

Figure 2 is an isometric view of the apparatus for positioning the collector to the collector frame, and forming a cell sub-assembly, this apparatus hereinafter being called jig A, the figure having cutaway portions for the purpose of clarity and showing a portion of the collector and collector support frame in position. and

Figure 3 is a sectional elevation of one of a plurality of bosses, a pair of such bosses forming a locator and forming a portion of the jig A, and

Figure 4 is a schematic plan view illustrating the action of the above mentioned locators of jig A in positioning, gaging and registering a collector for assembly into a collector-collector frame sub-assembly, and

Figure 5 is a partially sectioned elevation depicting the collector-collector support frame sub-assembly positioned in jig A, and

Figures 6 and 7 are isometric, partially sectioned and disengaged views of portions of the operative mechanism forming part of the jig A.

The construction of a completed cell includes two major assembly sequences, the assemblies so-made then being combined into a completed cell. One sequence of assembly operations includes assembly of a collector and collector support frame to form a sub-assembly, and then the addition of diaphragm screens to that sub-assembly to form one of the two major assemblies cited above. The other sequence of assembly operations includes the addition of anodes to a cell base, then the addition of cell shell portion, a cathode, and an upper or final cell shell portion to form the second major assembly.

The above described assembly operations are schematically illustrated by Figure 1 which shows the flow of separate cell components into sub-assemblies and the relationship of these components and sub-assemblies to the figures of the present invention. Referring to Figure l, a set of anodes and a cell base are combined, using jig C. A cell shell portion, and part of the cell lining are then added, and a cathode is then fitted to this base subassembly using a jig D to provide proper spatial relations. To this assembly is added an upper cell shell using jig E for correct alignment.

The other major sequence of assembly operations involves firstly the combination of a collector and collector support frame into a sub-assembly, using jig A. This subassembly and a set of diaphragms me then combined in another apparatus jig B, to complete the collector-collector frame-diaphragm assembly. This assembly is then transported in a transport jig F and is combined with the base assembly to form a completed cell.

The details of construction and operation of jig A, for gaging a collector and establishing the sub-assembly of collector and collector support frame, are given in Figures 25, inclusive. Figure 2 is an isometric partially sectioned view of the jig A, a segment of a collector in operative relationship to the jig being shown. Figure 3 is an elevation showing a cross-section of a collector, and a collector support frame in operative relation to elements of jig A, and Figures 4 and 5 are sectional detail illustrations of certain elements of jig A.

Referring to Figure 2, jig A is shown, this jig including a base 11 and a superstructure including a plurality, generally four, of upright columns 12 which rigidly support a horizontally disposed frame 13. Attached to and forming part of the jig base 11 is a collector aligning mechanism 21. The aligning mechanism 21 includes mechanism hereafter described. A hearing plate 23, corresponding generally in outline to the outline of the bottom of a collector is centrally and rigidly attached to the upper surface of the housing 22. The surface of the bearing plate 23 is in a plane paralleling the plane of the upper surface of the superstructure frame 13, and more specifically, the plane defined by registration plates attached to numbers of the superstructure frame 13.

Projecting through openings in the bearing plate 23 are two sets, of two each, of locators, these locators 24 24 34 34 each being a pair of lugs or bosses as later described. Each set of locators thus consists of two pairs of two bosses each, and therefore each locator defines a rectangle in a horizontal plane. The two locators of each rectangle are capable of limited movement here after more explicitly defined. Generally, however, one set of locators (bosses 24 24 are adapted to engage the outward walls of one diagonal pair of cylindrical ports or openings of a collector. This is termed the unidirectional set. The other set of locators (bosses 34 34 termed the bidirectional set, are adapted to engage by generally outward movement, the outward walls of a second diagonal pair of collector ports.

Mechanism hereafter described is provided for movement of the pairs of bosses in each set toward or from the center of the bearing plate 23. An operating wheel 25 provides for actuating the mechanism for providing movement of the locator bosses 24 24 of the unidirectional set. Movement of one pair is accompanied by an equal and corresponding movement of the other pair of the set. In other words, movement of the bosses 24 of one pair toward the center of the bearing plate is accompanied by an equal movement of the bosses 24 of the opposite pair toward the center. Thus, it is seen that the bosses 24 24 of the unidirectional set always define a rectangle havinge a fixed center, a constant width and a variable length.

With respect to the bosses 34 34 of the bidirectional set, and operating wheel 35 provides for actuating mechanism providing movement of the pairs of bosses 34 34 to or from each other as the case may be. It is seen that the bosses 34 34 of the bidirectional set always are located on the corners of a rectangle having a constant width. However, the long dimensions of the rectangle so defined can be at a variable angle to the long dimension of the rectangle defined by the bosses 24 24 of the unidirectional set. Further, the center of the bidirectional bosses 34 34 rectangle is movable, and may or may not coincide with the center of the rectangle of the unidirectional boss rectangle.

The disposition of the rectangle defined by the centers of the bidirectional bosses 34- 34 is visually indicated, and made available for a size and alignment check by an extension 33 projecting through the side of the housing 22. The extension 33 has a machined hole for loosely receiving a tolerance pin 31. A bracket 32 mounted generally below the extension and rigidly to the side of the housing 22, also has a machined hole therein for snugly receiving the pin 31. Accordingly, passage of the tolerance pin through the opening in the extension 33, and reception in the hole in the bracket 32 means that the general disposition of the bidirectional bosses 34 34 with respect to the unidirectional bosses 24 24- is constant within a certain tolerance range. The center line of the pin 31. in position in the receptacle provided in the angle 32 is, in elfect, a fixed reference point to which the other portions of the jig A, and the parts of the sub-assembly established with the figure, bear an explicit relation.

The functioning of the two sets of bosses is further illustrated by Figure 4 which is a schematic plan view showing the position of the sets of bosses 24 24 34 34 in operative contact with the wall surfaces of the circular ports of a collector. It will be seen that each of the two sets of bosses are adapted to engage by outward movement the walls of a diagonal pair of the ports of a collector.

The superstructure of the jig A includes a frame 33 having special corner members 14 on which are per the ends of the channel members.

manently mounted registration plates 15. An indexing mark 16 is scribed on each of the registration plates 15. The operative relation of a collector support frame 51 to the jig frame and registration plates 15 is shown in part by Figure 5 and in part by Figure 2. Referring to Figure'5, a collector casting 41 is shown in partial section, resting on the bearing plate 23 of the jig A. The collector casting includes four ports, the walls 42 42 of two of the ports being shown. The ports open into a central dome 43 which terminates in a flanged opening 44 for connection, in an operating'cell to a chlorine duct. The dome 43 is permanently attached to a ring member 45, which is attached to fourvertical support members 46, having a threaded portion at'the upper end thereof. The manner of attachment of the'ring member 45 and support members 46 is shown in Figure 15.

The collector support frame 51 includes two long channel members 52 and two cross members 53, the cross members being suitably angle irons set in slightly from The support members from the ring member are attached to the collector support frame by bolting to supplemental cross members 54. When a collector-collector support-frame is properly assembled within the jig A, a constant clearance is measurable between the underside of the ends of the channel members 52 and the registration plates 15. Further orientation of the collector support is provided by registration marks 55 in the frame cross members 53, and similar marks 56 in the webs of the channel members 52. These latter are aligned with registration marks 17 on pillow, blocks 18 mounted on the jig frame and defining a line at right angles with a line.

between the registration marks 16 on the opposite corners of the jig.

In using jig A to establish a sub-assembly of a collector and collector frame, the operator first provides, through hand-wheel 25 inward movement of the bosses of the unidirectional set to their stopping point. Next, with pin 31 removed, bosses 34 34 of the bidirectional set are moved inwardly to their stopping point by operation of hand-wheel 35. The collector, with the collector support frame loosely attached thereto by'the support bolts, is then lowered'on to the bearing plate 23. The operator then moves the bosses 24 24 of the unidirectional set outwardly to make contactwith theinner surface of two of the collector outlet ports. This operation locates these two collector port walls generally equidistant from the center of the jig A (the boss pairs of this set being movable only equidistant from the jig center) and also thus positions generally the collector on a line coinciding generally with a line equidistant between the bosses of each pair of the set. Thus, referring to Figure 4, it is seen that first the collector is adjusted and positioned by the action of the unidirectional Then the operator, by rotating hand-wheel 35,

Figure 4, it will be seen that if the collector ports define v perfect circles, and these circles are centered on the corner of a perfect square, then all four bosses 34 34 of the bidirectional set will engage the collector port walls. In addition, the long dimension of the rectangle formed by the bidirectional bosses will be precisely at right angles to the long dimension of the rectangle defined by the unidirectional bosses 24 24 On the other hand, if the above mentioned desired relationships of the collector ports do not exist owingto warpage of the collector, when any of the bidirectional bosses 34 ,34 make Contact with a collector port wall, further outward'movement will be normally accompanied by rolling movement along the wall and radial shifting, and possibly lateral shifting, of the rectangle defined by the bidirectional bosses 34 34 By lateral shifting is meant that the long axis of the rectangle defined by the bidirectional bosses 34 34 is shifted to a different bisecting point with respect to the rectangle defined by the unidirectional bosses 24 24 This lateral shifting may also be accompanied by a change in the angle of intersection of the long axes of the rectangles. This shifting is, of course, reflected in the position of the extension 33.

It is seen that the position of the extension 33 provides,

by reference to the bracket 32, an integrated indication of the position of the rectangle defined by the bidirectional set of bosses relative to the rectangle defined by the unidirectional set. This indication integrates lateral, lineal and angular position of the two said rectangles in the horizontal plane. A rapid tolerance determination based on this integrated indication is possible with the pin 31. The pin is inserted through the hole in the extension 33, and if it is possible to insert the pin 31 further into the receptacle in the bracket 32,-it is established that the collector is properly aligned and meets the required port location specifications. If the pin is thus received in the receptacle in the bracket 32, the collector frame is rigidly secured to the collector with thereference marks 16, 55, '17, 56 already mentioned being properly registered.

Figure 7 is an enlarged, partially sectional view of one pair of bosses 24 of the unidirectional bosses and operating mechanism therefor, forming a portion of jig A. Referring to Figure 7, the pair of bosses 24 are slidably mounted on a movable plate 26 The movable plate 26 is supported by slides, not shown, attached within the housing 22. Rotation of the hand-wheel 25 causes rotation of a threaded shaft 27 by actuating a stub shaft 28 and a bevel gearset 29. Movement of the threaded shaft 27 along its axis is prevented by a double thrust bearing, not shown, engaging the shoulder of an enlarged section 30 of the threaded shaft 27. The other pair of bosses 24 not shown, also operatively engage a threaded section of the shaft 27, the thread lead being opposite in direction but of equal pitch to the threaded portion actuating movement of the opposite boss 24 pair. Thus rotation of the hand-wheel 25 causes equal movement of the boss pairs 24;, 24 in opposite directions.

The mechanism for actuation of the bidirectional bosses 34 34 is illustrated by Figure 6, this figure being an isometric sectional view of a portion of the collector aligning mechanism 21. Referring to Figure 6, one pair 34 of the bidirectional bosses is shown. The bosses 34 are attached to a slidable plate 36,, supported adjacent to a support plate 37 by slides not shown attached to the support plate 37. Movement of the slidable plate 36 is provided by rotation of a threaded shaft 38 which extends through the wall of the housing 22 and is fastened to the operating wheel 35. The support plate 37 supports also a second slidable plate not shown which in turn conveys a second pair of bidirectional bosses 34 The support plate 37 is mounted within the housing by bearing support means not shown which permits limited rotational movement, and lateral and lineal movement, all in a horizontal plane. From the foregoing it is seen that outward movement of the boss 34 34 pairs can be accompanied by a shift in the disposition of the rectangle defined by the bosses with respect to its angle to the unidirectional boss rectangle and also with respect 'to the position of its center relative to the invariant center of the rectangle defined by the unidirectional bosses.

From the foregoing, it will be seen that, in operation, the bosses 24 24 34 34 Will normally go through limited movement along the walls of the collector ports. This movement may be by sliding contact, but it has been found that .rolling contact is particularly effective and desirable. A preferred design for the bosses is illustrated in Figure 3, this figure being a sectional elevation of an embodiment of a boss providing frictionless rolling contact. Referring to Figure 3, the boss assembly in- .cludes a .pedestal e2 which is mounted upon the slidable plate 26 and attached thereto by cap screw 63. A collar 64 is positioned by the shank of the pedestal 62. The .top of the pedestal 62 has preferably a rolled crown as shown. A roller 65 is positioned by the pedestal and supported by the collar 64, the lowermost surface 66 of the roller is positioned slightly above the top level of the bearing plate 23. The wall &2 of the collector port engages the periphery of the roller 65. A chamfer 67 on the upper portion of the roller 65 is an extension of the outline of the crown of the pedestal 62. This continuity of outline is beneficial in several respects. In lowering .the collector casting in place, this inclusion facilitates placement. In addition the disposition of the extremities of the pedestal crown from the roller periphery assures that rolling contact is maintained in aligning the collector despite the occasional presence of minor surface protrusions.

Upon completion of the collector-collector frame subassembly as above described, it is available for addition of the diaphragms to complete the cell top assembly.

In a preferred embodiment of the invention, the jigs A and B are employed also in conjunction with additional devices for construction and assembly of the aforementioned cell base and cell shell as will be described hereafter. The general sequential relationships in this embodiment are illustrated again by Figure 1, wherein is shown the schematic combination of anode sticks and a cell base, employing a jig C, thus forming a base sub-assembly. To this is combined a cathode casting, its relationship to the base-anode sub-assembly being ascertained and determined by jig D, and a cell shell being then provided, its relationship to the preceding sub-assembly being determined by a jig E.

From the foregoing, it will be seen that the described apparatus can be employed to assemble a collector-collector support frame and concurrently gage this completed assembly for incorporation into another sub-assembly, viz. a collector-collector support framediaphragm sub-assembly which constitutes the upper portion of the cell. The upper portion of the cell can then be joined to the lower portion to complete the major portion of the cell assembly. Further steps to render the cell operable would include the connection of an appropriate chlorine line to the collector opening, and the attachment of the necessary electrical connections, etc.

In a careful comparison of the performance of a group of cells constructed with the apparatus of our invention with performance of a group constructed according to previous methods it was found that the former group provided an increase of approximately percent in current efficiency. In addition, it was found that the average elfective life of the former group of cells was a significant improvement over the preceding practice, particularly with respect to the diaphragm life. Since the cost of construction of cells with the present apparatus is substantially the same as by the former practices, it is apparent that our apparatus is highly beneficial and economical.

Having described the apparatus of our invention in somedetail and the manner of its use, what we claim is:

1. An apparatus for gaging a collector for an electrolytic cell, the collector having four cylindrical ports opening in the lower face thereof and centered on the corners of an approximate square, comprising; a casing including a top horizontal plate for supporting the collector, and indicator as hereafter defined, and unidirectional and bidirectional locator mechanisms as hereafter defined, each locator mechanism including at least two contacts spaced apart horizontally and projecting above the said top horizontal plate through apertures permissive of horizontal movement of said contacts, for contacting the walls of the ports of a collector when in position on the horizontal plate, the unidirectional locator mechanism including means for linearly moving the contacts thereof on a straight fixed line in opposite directions and equally in unison, whereby outward movement of the contacts can engage the outward walls of a diagonal pair of collector ports and uniformly position the collector with respect to the said fixed line, the bidirectional locator mechanism including a horizontal support plate slidably supported adjacent the said top horizontal plate, the contacts being slidably supported on said plate, and means for linearly moving the contacts in a straight line in opposite directions and equally in unison; the said line having a normal position intersecting the fixed line of the unidirectional locator mechanism at the mid-point of and at right angles thereto, but angularly and horizontally shiftable from said normal position with movement of the support plate, whereby outward movement of the contacts and engagement with this outward wall of the second diagonal pair of collector ports provide horizontal and angular location of the slidable support plate with respect to the fixed line of the unidirectional lo cator mechanism and the midpoint thereof, the indicator including a fixed position element and a movable element, the movable element being operatively attached to the slidable support of the bidirectional locator mechanism at, a position remote from the center thereof, the movable element being vertically aligned with the fixed element when the bidirectional locator mechanism is normally positioned, whereby horizontal and angular displacement of the bidirectional locator mechanisms is indicated by displacement of the movable element from said vertical alignment. 7

2. The apparatus of claim 1 further defined in that the contacts of each locator in each set of locators define rectangles of constant width and variable length centered lengthwise on the fixed and movable lines respectively.

3. The apparatus of claim 2 wherein each contact is a boss including a top upwardly converging portion adapted to guide a vertical wall of a collector port in downward movement in positioning a collector, and a rotatable cylindrical portion for providing rolling contact with a positioned collector port wall.

4. Apparatus for gaging and assembly of a collector for an electrolysis cell and a support frame therefor 'including apparatus in accordance with claim 1, and. a supported frame parallel to and above the horizontal top plate of the collector gager, and registration marks in said frame defining the intersection of two vertical planes and one pair of registration marks defining a horizontal plane, whereby a collector support frame is registrable horizontally and vertically with respect to a located collector.

5. An apparatus for gaging an electrolytic cell collector that has a lower face with downwardly opening generally cylindrical ports arranged in opposed sets, said apparatus including a fixed horizontal base support shaped to receive the lower face of the collector, a first locator mechanism held by said support and having a set of bosses horizontally spaced diagonally of the support and projecting above the top of the support, said locator mechanism also having means for linearly moving the bosses along said diagonal in opposite directions with respect to the support, and equally in unison, to engage diagonally opposite internal surface portions of the collector walls, a second locator mechanism including a sec.- ond set of horizontally spaced bosses on a horizontally slidable carrier held by the support, the second set of bosses projecting upwardly above the top of the support, the second locator mechanism also having means for linearly moving the second set of bosses along a different diagonal line in opposite directions and equally in unison to engage other diagonally opposite internal surface portions of the collector walls and to then cause their slidable carrier to take a position indicative of the trueness of the collector, and indicator means including a fixed indicator element fixed on the base support and a movable indicator element fixed on the slidable carrier at a position remote from the point where the diagonal lines cross, to indicate by the aligmnent of these elements with each other the horizontal and angular trueness of the collector.

References Cited in the file of this patent UNITED STATES PATENTS Love Dec. 12, 1922 Buckwalter Oct. 6, 1931 Evans et a1. Feb. 22, 1944 Midtlyng Sept. 23, 1947 Krurnm Aug. 18, 1953 Wilken et a1. Sept. 15, 1953 

